Boot liner

ABSTRACT

A boot liner basically includes a sole portion, an upper portion and a tightening device. A tongue part is preferably mounted in a slit formed in the upper portion. The upper portion has a thermoformable layer with first and second non-thermoformable members located on an inner side and an outer side of the ankle section. The first and second non-thermoformable members are banana-shaped or L-shaped pads that are preferably formed of a polyurethane. The first and second non-thermoformable members are preferably located below and rearwardly the portions of the tibia and fibula that form the ankle of a foot corresponding to the size of the boot liner.

BACKGROUND OF THE INVENTION

[0001] 1. Field of the Invention

[0002] This invention generally relates to a boot liner. Morespecifically, the present invention relates a sport boot liner orsnowboard boot liner that is comfortable to wear.

[0003] 2. Background Information

[0004] Many cold weather footwear have an internal boot liner that isseparate from the outer shell of the footwear. For example, hikingboots, ski boots, snowboard boots and the like often have a boot liner.The boot liner provides thermal insulation, shock absorption, comfort,etc. for the wearer's foot and/or the lower part of the wearer's leg.The boot liner is typically formed with a sole and an upper portion. Theupper portion is often formed with a central opening or slit. Some timesa tongue is formed on a lower end of the opening or slit, the tongueextending between the sides of the central opening or slit.

[0005] It is important to keep the liner in contact with the wearer'sfoot. Thus, the boot liner is sometimes provided with a tighteningdevice. The tightening device is typically positioned on the sides ofthe central slit and usually includes loops or eyelets with a laceextending through the loops or eyelets. The lace typically extendsthrough the loops or eyelets in a criss-cross manner, e.g., going fromside to side through the loops and eyelets. Typically the eyelets orloops are formed on opposite sides of the opening in equal numbers atequally spaced apart intervals, defining pairs of eyelets or loops.

[0006] Boot liners are formed of a variety of materials such as wovenfabrics, sponge like materials or rubber, or various combinations ofthese materials. Some boot liners are provided with a tightening devicethat can tighten the boot liner around wearer's foot.

[0007] One example of a boot liner with a tightening device is disclosedin U.S. Pat. No. 5,937,542, assigned to Solomon S. A. This patentdiscloses a tightening device for a boot liner that uses a single cordand a plurality of straps to tighten the boot liner about the wearer'sfoot.

[0008] Recently, the boot liner has been redesigned to provide thewearer with a more comfortable fit. For example, U.S. Pat. No. 5,924,218assigned to Salomon S. A. discloses a boot liner that utilizes thermoforming material to provide a better fit.

[0009] In view of the above, there exists a need for snowboard bootliner which is comfortable to wear. This invention addresses this needin the prior art as well as other needs, which will become apparent tothose skilled in the art from this disclosure.

SUMMARY OF THE INVENTION

[0010] One object of the present invention is to provide a snowboardboot liner that is comfortable to wear.

[0011] Another object of the present invention is to provide boot liner,which is securely tighten about the wears ankle.

[0012] The foregoing objects can basically be attained by providing asnowboard boot liner comprising a sole portion and an upper portion. Theupper portion has a foot section fixedly coupled to the sole portion, anankle section extending upwardly from the foot section and a leg sectionextending upwardly from the ankle section. The upper portion includes athermoformable layer located on an inner side and an outer side of theankle section and a first non-thermoformable member located in one ofthe inner and outer sides of the ankle section.

[0013] These and other objects, features, aspects and advantages of thepresent invention will become apparent to those skilled in the art fromthe following detailed description, which, taken in conjunction with theannexed drawings, discloses a preferred embodiment of the presentinvention.

BRIEF DESCRIPTION OF THE DRAWINGS

[0014] Referring now to the attached drawings which form a part of thisoriginal disclosure:

[0015]FIG. 1 is a side perspective view of a boot liner in accordancewith the present invention;

[0016]FIG. 2 is a front perspective view of the boot liner illustratedin FIG. 1;

[0017]FIG. 3 is an enlarged, partial cross-sectional view of the bootliner illustrated in FIGS. 1 and 2 as viewed along section line 3-3 ofFIG. 2;

[0018]FIG. 4 is an enlarged, partial cross-sectional view of the bootliner illustrated in FIGS. 1-3 as viewed along section line 4-4 of FIG.3;

[0019]FIG. 5 is a partial cross-sectional view of a portion of the bootliner illustrated in FIGS. 1-4 as viewed along section line 5-5 of FIG.4; and

[0020]FIG. 6 is a partial cross-sectional view of a portion of the bootliner illustrated in FIGS. 1-5 as viewed along section line 6-6 of FIG.4.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0021] Referring initially to FIGS. 1 and 2, a boot liner 10 isillustrated in accordance with a preferred embodiment of the presentinvention. The boot liner 10 is preferably designed to be used with asport boot (not shown) or the like. More specifically, the boot liner 10is designed to be inserted into a shell of a sport boot such as asnowboard boot (not shown). The boot liner 10 allows for a tight fitaround the foot and lower leg of the wearer. More specifically, the bootliner 10 of the present invention allows a tight fit around the anklearea of the wearer.

[0022] It would be apparent to the one skilled in the art from thisdisclosure that the boot liner 10 can come in a variety of sizes toaccommodate various sizes of feet. In other words, the boot liner 10 isso dimensioned to correspond to a particular size of foot for aparticular size of boot liner. As explained below, the boot liner 10 isespecially constructed to provide a tight fit around the ankle area ofthe wearer. Thus, for a given size of foot, the boot liner 10 is shapedto snuggly fit the ankle joint A which is basically comprised of threebones, i.e., the tibia which forms the inside or medial portion of theankle joint, the fibula which forms the lateral or outside portion ofthe ankle joint and the talus that forms the underneath of the anklejoint. The boot liner 10 of the present invention is designed based onthe average location of the ankle joint A formed by the tibia and thefibula portions of the ankle joint A to a particular size of foot.

[0023] The boot liner 10 basically includes a sole portion 12, an upperportion 14 coupled to the sole portion 12 and a tightening device Tcoupled to the upper portion 14 for drawing opposite lateral sides ofthe upper portion 14 together via a lace or cord L. As used herein, thefollowing directional terms “forward, rearward, above, downward,vertical, horizontal, below and transverse” as well as any other similardirectional terms refer to those directions of the boot liner 10 in thenormal upright position. Accordingly, these terms, as utilized todescribe the present invention should be interpreted relative to awearer's foot with the boot liner 10 in the normal upright position.

[0024] As best seen in FIG. 4, the sole portion 12 is preferably aseparate element that is coupled to the upper portion 14 in aconventional manner such as by sewing the two portions together.Preferably, the sole portion 12 is preferably different from the upperportion 14. The sole portion 12 is preferably a two part constructionwith each part being constructed of two layers of flexible material.Specifically, the sole portion 12 has an outer sole section 15 that issewn to the upper portion 14 and an inner sole section 16 the removablyoverlies the outer sole section 15.

[0025] More specifically, as seen in FIG. 4, the outer sole section 15should have a bottom outer layer 15 a and an inner layer 15 b. Thislayered configuration is preferably bonded together in a conventionalmanner such as with adhesives. In the drawings, the thickness of each ofthe layers 15 a and 15 b is not drawn to scale. Rather, the thickness ofthe layer 15 a has been exaggerated for purposes of illustration.

[0026] The outer layer 15 a of the outer sole section 15 is constructedof a material having a high coefficient of friction. In other words,when the boot liner 10 is located within the boot (not shown) the soleportion 12 will frictionally contact the inner surface of the boot tolimit relative movement therebetween. The outer layer 15 a of the outersole section 15 is preferably constructed of a flexible rubber materialsuch as a synthetic rubber, a polyvinyl chloride (PVC), ethyl vinylacetate copolymer (EVA) or leather or any other suitable material. Thebottom surface of the outer layer 15 a of the outer sole section 15 ispreferably textured to increase the non-slip characteristics thereof.The inner layer 15 b of the outer sole section 15 is preferably formedof a thermoformable material such as ULTRALON, which can conformed thebottom of the foot. In other words, the thermoformable inner layer 15 bof the outer sole section 15 has thermoplastic qualities renderingcapable of being adjusted and/or adapted after being heated at itsthermoforming temperature, to the specific volume of the wearer's foot.

[0027] As seen in FIG. 4, the inner sole section 16 is preferably aremovable insert that overlies the outer sole section 15. The inner solesection 16 is preferably constructed of a bottom layer 16 a and an upperlayer 16 b. This layered configuration is preferably bonded together ina conventional manner such as with adhesives. In the drawings, thethickness of each of the layers 16 a and 16 b is not drawn to scale.Rather, the thickness of the layer 16 b has been exaggerated forpurposes of illustration. The bottom layer 16 a of the inner solesection 16 is preferably constructed of a compressible, flexiblematerial such as an ethyl vinyl acetate copolymer (EVA) that provides acushion for the wearer's foot. The upper layer 16 a of the inner solesection 16 is preferably formed of a polyester fabric or textilematerial.

[0028] The upper portion 14 is preferably constructed of two parts,e.g., a main part 17 and a tongue part 18. These parts 17 and 18 aresewn together by stitching 19 to form a foot section 20, an anklesection 21 and a leg section 22. The foot section 20 is fixedly coupledto the sole portion 12 in a conventional manner, preferably by stitching21. The ankle section 21 is located in the area between the foot section20 and the leg portion 22. The leg portion 22 extends upwardly from thefoot section 20 with a longitudinal slit 24 formed in both the footsection 20 and the ankle section 21. The longitudinal slit 24 issubstantially located along the middle or median plane of the boot liner10. Thus, the longitudinal slit 24 is defined by a pair of oppositelateral sides 26 a and 26 b of the upper portion 14. Preferably, thelongitudinal slit 24 extends along both the foot section 20 and the legsection 22.

[0029] As seen in FIGS. 3-6, each of the parts 17 and 18 of the upperportion 14 is constructed of four layers of flexible materials as bestseen in FIGS. 5 and 6. More specifically, the upper portion 14 has anoutermost layer 28 a, an outer intermediate or thermoformable layer 28b, an inner intermediate or spongy layer 28 c and an innermost layer 28d. This layered configuration is preferably bonded together in aconventional manner such as with adhesives. In the drawings, thethickness of each of the layers 28 a-28 d is not drawn to scale. Rather,the thickness of each of the layers 28 a and 28 d has been exaggeratedfor purposes of illustration.

[0030] In the preferred embodiment, the outermost layer 28 a ispreferably constructed of an elastane material such as spandex. Theoutermost layer 28 a preferably has a lateral thickness or dimension ofapproximately 0.3 millimeters to approximately 0.5 millimeters. Theouter intermediate (thermoformable) layer 28 b is preferably constructedof a thermoformable material such as ULTRALON. The thermoformable layer28 b has thermoplastic qualities rendering capable of being adjustedand/or adapted after being heated at its thermo forming temperature, tothe specific volume of the wearer's foot. The thermoformable layer 28 bpreferably has a lateral thickness or dimension of approximately 7millimeters. The inner intermediate (spongy) layer 28 c is preferablyconstructed of a conventional foam or sponge material such as an opencell polyurethane. The inner intermediate layer 28 c preferably has alateral thickness or dimension of approximately 3.5 millimeters. Theinnermost layer 28 d is preferably constructed of a cloth material suchas a NYLEX® polymer knit fabric. The innermost layer 28 d preferably hasa lateral thickness or dimension of approximately 0.3 millimeters toapproximately 0.5 millimeters. Of course, it will be apparent to thoseskilled in the art from this disclosure that the upper portion 14 can beconstructed of other suitable flexible materials that will carry out thepresent invention.

[0031] As seen in FIG. 3, the ankle section 21 has a pair ofnon-thermoformable members 29 located in the inner and outer sides ofthe ankle section 21. As seen in FIGS. 5 and 6, the first and secondnon-thermoformable members 29 are preferably located between thethermoformable layer 28 b and the inner spongy layer 28 c. The first andsecond non-thermoformable members 29 are banana-shaped or L-shaped padsthat are preferably formed of a polyurethane material. The first andsecond non-thermoformable members 29 form a pair of banana-shaped orL-shaped bulges B that extend laterally towards each other.

[0032] As seen in FIG. 4, each of the first and secondnon-thermoformable members 29 has a vertical height or dimension D₁ ofapproximately 70 millimeters and a horizontal length or dimension D₂ ofapproximately 70 millimeters. The non-thermoformable members 29preferably have a lateral thickness or dimension D₃ of approximately11.5 millimeters. The tightening device T is arranged and configured onthe upper portion 14 such that first and second strap portions overlieparts of the non-thermoformable members 29 as best seen in FIG. 4.

[0033] The non-thermoformable members 29 are positioned just rearwardlyof an average location of the fibula and tibia that form portions of theankle joint. In other words, the non-thermoformable members 29 basicallycradle or support the ankle joint at the bottom and rearward sides ofthe ankle joint A. Of course, it would be apparent to those skilled inthe art from this disclosure that for each size of boot liner 10, thelocation of the non-thermoformable members 29 should be located based onthe average location of the ankle joint A for a wearer's foot that issized for the particular size of boot liner 10.

[0034] The density of the thermoformable material forming thethermoformable layer 28 b is preferably around 50 kg/m3 and has ahardness of approximately 35-40 on a rubber hardness tester C scale ofthe Japan Rubber Association. On the other hand, the polyurethanematerial of the non-thermoformable members 29 preferably have a hardnessof 20 on the rubber hardness tester C scale of the Japan RubberAssociation. The polyurethane material of the non-thermoformable members29 is denser such that the non-formable members 29 are not ascompressible as the spongy layer 28 c. Thus, the thermoformable layer 28b is harder than the inner intermediate layer 28 c and thenon-thermoformable members 29. The non-thermoformable members 29 arepreferably harder than the spongy layer 28 c. Preferably, both thespongy layer 28 c and the non-thermoformable members 29 are formed of apolyurethane material. However, the non-thermoformable members 29 arenot as dense as the thermoformable layer 28 b such that thenon-thermoformable members 29 are more compressible in the lateraldirection than the thermoformable layer 28 b.

[0035] As seen in FIG. 3, the tongue part 18 is arranged to span thelongitudinal slit 24 as seen in FIGS. 1 and 2. The tongue part 18 ispreferably constructed of four layers 30 a, 30 b, 30 c and 30 d.Preferably, the materials of the layers 30 a, 30 b, 30 c and 30 dcorresponds to the same materials used for the layers 28 a, 28 b, 28 cand 28 d of the main part 17 of the upper portion 14, respectively.Accordingly, the tongue part 18 is constructed of a flexible cushionedmaterial, which is preferably the same flexible cushioning materialsused for the main part 17 of the upper portion 14. This layeredconfiguration is preferably bonded together in a conventional mannersuch as with adhesives. In the drawings, the thickness of each of thelayers 30 a-30 d is not drawn to scale. Rather, the thickness of each ofthe layers 30 a and 30 d has been exaggerated for purposes ofillustration.

[0036] The tightening device T is coupled to the upper portion 14 fordrawing opposite lateral sides 26 a and 26 b of the upper portion 14towards one another. The tightening device T basically includes an upperlacing member 32 and a lower lacing member 34. The upper and lowerlacing members 32 and 34 are sewn via stitching to the upper portion 14at four rearwardly located points 35 (only two points shown in FIG. 1).The lower lacing member 34 also has its two lateral bottom portionsglued to the outer sole section 15 at side points 36 (only one pointshown in FIG. 1). The upper lacing member 32 includes four (two pairs)upper strap or lacing portions 41, 42, 43 and 44, while the lower lacingmember 34 includes a pair of lower strap or lacing portions 45 and 46.The upper lacing member 32 primarily tightens the leg section 22 of theupper portion 14, while the lower lacing member 34 primarily tightensthe ankle section 21, which is located at the intersection of the footsection 20 and the leg section 22. Of course, it will be apparent tothose skilled in the art from this disclosure that depending upon thesize of the boot liner 10 and its desired used, fewer or more primarylacing portions can be utilized to carry out the present invention.

[0037] The strap or lacing portions 41-46 are preferably constructed ofconventional strap material that is commonly used in the art. The strapor lacing portions 41-46 are constructed of a flexible material such asleather, nylon or any other suitable material. Of course, a variety ofarrangements can be utilized. For example, the lacing portions 41-46 canbe merely eyelets or holes formed directly in the upper portion 14.Alternatively, the lacing portions 41-46 can be formed as hooks and/orrigid ring members.

[0038] The tightening device T is positioned on the sides of the centralslit 24 with the cord L extending through the looped members formed bythe lacing portions 4146. The cord L typically extends through thelooped members formed by the lacing portions 41-46 in a criss-crossmanner, e.g., going from side to side through the loops. Typically, thelooped members formed by the lacing portions 41-46 are located onopposite sides of the central slit 24 in equal numbers at equally spacedapart intervals so as to define pairs of looped members.

[0039] The terms of degree such as “substantially”, “about” and“approximately” as used herein mean a reasonable amount of deviation ofthe modified term such that the end result is not significantly changed.These terms should be construed as including a deviation of at least ±5%of the modified term if this deviation would not negate the meaning ofthe word it modifies.

[0040] While only selected embodiments have been chosen to illustratethe present invention, it will be apparent to those skilled in the artfrom this disclosure that various changes and modifications can be madeherein without departing from the scope of the invention as defined inthe appended claims. Furthermore, the foregoing description of theembodiments according to the present invention are provided forillustration only, and not for the purpose of limiting the invention asdefined by the appended claims and their equivalents.

What is claimed is:
 1. A boot liner comprising: a sole portion; and anupper portion having a foot section fixedly coupled to said soleportion, an ankle section extending upwardly from said foot section anda leg section extending upwardly from said ankle section, said upperportion including a thermoformable layer located on an inner side and anouter side of said ankle section and a first non-thermoformable memberlocated in one of said inner and outer sides of said ankle section. 2.The boot liner according to claim 1, wherein said firstnon-thermoformable member is located in said inner side of said anklesection.
 3. The boot liner according to claim 2, wherein said firstnon-thermoformable member is located in said outer side of said anklesection.
 4. The boot liner according to claim 3, wherein said upperportion includes a second non-thermoformable member located in saidinner side of said ankle section.
 5. The boot liner according to claim4, wherein said first a nd second non-thermoformable members arebanana-shaped pads.
 6. The boot liner according to claim 5, wherein saidfirst and second non-thermoformable members are formed of apolyurethane.
 7. The boot liner according to claim 5, wherein each ofsaid first and second non-thermoformable members has a height ofapproximately 70 millimeters and a length of approximately 70millimeters.
 8. The boot liner according to claim 7, wherein said upperportion includes a tightening device with a first strap portionoverlying a part of said first non-thermoformable member and a secondstrap portion overlying a part of said second non-thermoformable member.9. The boot liner according to claim 1, wherein said thermoformablelayer further extends along said foot section.
 10. The boot lineraccording to claim 9, wherein said thermoformable layer further extendsalong and a leg section
 11. The boot liner according to claim 10,wherein said upper portion includes a foam layer overly an exteriorlyfacing surface of said thermoformable layer.
 12. The boot lineraccording to claim 11, wherein said upper portion includes an outerlayer overly an exteriorly facing surface of said thermoformable layer.13. The boot liner according to claim 1, wherein said upper portionincludes an inner layer overly an interiorly facing surface of saidthermoformable layer with said first and second non-thermoformablemembers located between said thermoformable layer and said inner layer.14. The boot liner according to claim 1, wherein said firstnon-thermoformable member is a banana-shaped pad.
 15. The boot lineraccording to claim 1, wherein said first and non-thermoformable memberis formed of a polyurethane.
 16. The boot liner according to claim 1,wherein said first non-thermoformable member has a height ofapproximately 70 millimeters and a length of approximately 70millimeters.
 17. The boot liner according to claim 1, wherein said soleportion is a separate member that is coupled to said foot section ofsaid upper portion.
 18. The boot liner according to claim 17, whereinsaid sole portion is constructed of flexible materials.
 19. The bootliner according to claim 1, wherein said sole portion includes an outersole section that is fixedly coupled to said foot section of said upperportion.
 20. The boot liner according to claim 19, wherein said outersole section of said sole portion includes an exterior layer of apolyvinyl chloride material.
 21. The boot liner according to claim 20,wherein said outer sole section of said sole portion further includes aninterior thermoformable layer.
 22. The boot liner according to claim 21,wherein said sole portion further includes an inner sole section thatoverlies said outer sole section of said sole portion.
 23. The bootliner according to claim 1, wherein said sole portion further includesan thermoformable layer.
 24. The boot liner according to claim 1,wherein said upper portion includes a tongue portion coupled to saidupper portion and arranged to span a longitudinal slit formed in saidleg section, and a tightening device coupled to said upper portion fordrawing opposite lateral sides of said upper portion that define saidslit towards one another.
 25. The boot liner according to claim 19,wherein said tightening device includes a first strap portion overlyinga part of said first non-thermoformable member and a second strapportion overlying a part of said second non-thermoformable member.